US20200227577A1 - Solar cell backsheet - Google Patents

Solar cell backsheet Download PDF

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Publication number
US20200227577A1
US20200227577A1 US16/832,053 US202016832053A US2020227577A1 US 20200227577 A1 US20200227577 A1 US 20200227577A1 US 202016832053 A US202016832053 A US 202016832053A US 2020227577 A1 US2020227577 A1 US 2020227577A1
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Prior art keywords
layer
parts
thickness
milky
adhesive
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Inventor
Xiang-An Liu
Qiang Wang
Tong-Xin Wang
Kun Chen
Ming-Long Ji
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Zhongtian Photovoltaic Materials Co ltd
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Zhongtian Photovoltaic Materials Co ltd
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Assigned to ZHONGTIAN PHOTOVOLTAIC MATERIALS Co.,Ltd. reassignment ZHONGTIAN PHOTOVOLTAIC MATERIALS Co.,Ltd. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHEN, KUN, JI, Ming-long, LIU, Xiang-an, WANG, QIANG, WANG, Tong-xin
Publication of US20200227577A1 publication Critical patent/US20200227577A1/en
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/049—Protective back sheets
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J175/00—Adhesives based on polyureas or polyurethanes; Adhesives based on derivatives of such polymers
    • C09J175/04—Polyurethanes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J133/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Adhesives based on derivatives of such polymers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H01L31/1876—Particular processes or apparatus for batch treatment of the devices
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the subject matter herein generally relates to solar cells, and more particularly to a solar cell backsheet.
  • a crystalline silicon solar cell module generally includes eight elements: glass, a packaging film, a cell sheet, solder tape, silicone, an aluminum frame, a junction box, and photovoltaic backsheet.
  • the photovoltaic backsheet is an extremely important packaging material in photovoltaic modules.
  • the photovoltaic backsheet supports the cell sheet while directly contacts a large area of the external environment, it provides important functions of ensuring stable photovoltaic power generation for 25 years, and insulation and barrier, weatherability, reliability, and longitivity of the solar cell.
  • Conventional photovoltaic backsheets generally have a layer of adhesive film added between the backsheet and the cell sheet, and be covered with this adhesive film.
  • Using an integrated adhesive film-backsheet structure may introduce defects in use.
  • the integrated adhesive film-backsheet structure of the solar photovoltaic module comprises an EVA substitute layer, a structural reinforcement layer, and a weathering layer in said sequence from the outer layer facing the cell sheet.
  • the EVA substitute layer is a single-layer structure.
  • the EVA substitute layer After lamination, there are many defects, which are mainly manifested as: (1) after lamination, the EVA substitute layer is squeezed by the structural reinforcement layer and glass, and a phenomenon of edge overflow and delamination may occur; (2) the EVA substitute layer is a micro-foamed polyolefin structure, which is relatively soft, and during the lamination process, the cell sheet and the solder tape completely penetrate the EVA substitute layer and directly contact the structural reinforcement layer, which may cause the cell sheet to crack and fragment; (3) more serious defects are due to the conductor completely penetrating the EVA substitute layer, the EVA substitute layer completely loses its insulating function, so that only the weathering layer and the structural reinforcement layer are relied on for insulation, and the overall insulation thickness is reduced.
  • the present disclosure discloses a solar cell backsheet, the photovoltaic backsheet from outside to inside including a weathering layer, an adhesive layer, a PET layer, an adhesive layer, and a functional layer, the functional layer including an integrally formed milky layer and a transparent layer, wherein the milky layer includes at least one layer and has a thickness of 20-200 ⁇ m, and includes at least 3 parts of a modified inorganic filler, at least 70 parts of a modified resin, at least 0.3 parts of a UV absorber, and at least 0.3 parts of an antioxidant.
  • the transparent layer is bonded to the cell sheet, includes at least one layer and has a thickness of 200-800 ⁇ m, and includes at least 90 parts of a modified resin, at least 0.3 parts of a UV absorber, and at least 0.3 parts of an antioxidant.
  • the milky layer includes a plurality of layers.
  • the content of the modified resin in the layer of the milky layer bonded to the transparent layer is not higher than the content of the modified resin in the milky layer bonded to the adhesive layer, and the thickness of the layer of the milky layer combined with the transparent layer is not higher than the thickness of the layer of the milky layer bonded to the adhesive layer.
  • the transparent layer includes a plurality of layers.
  • the content of the modified resin in the layer of the transparent layer bonded to the cell sheet is not lower than the content of the modified resin in the layer of the transparent layer bonded to the milky layer, and the thickness of the layer of the transparent layer bonded to the cell sheet is not higher than the thickness of the layer of the transparent layer bonded to the milky layer.
  • the weathering layer has a thickness of 5-200 ⁇ m and is a fluorine-containing or non-fluorine-containing layer.
  • the adhesive layer is an acrylic adhesive, a urethane adhesive, an epoxy resin adhesive, or a resin adhesive having a thickness of 5-30 ⁇ m.
  • the modified resin is one or a combination of polyethylene, polypropylene, an ethylene copolymer, a polyolefin elastomer, and a polyolefin plastomer.
  • the modified inorganic filler is one or a combination of titanium dioxide, montmorillonite, kaolin, mica, talc, wollastonite, and brucite.
  • the modification method used is a wrapping method, a chemical vapor precipitation method, a local chemical reaction method, a low temperature plasma method, a high energy radiation method, an electron beam ray method, or an ultraviolet method.
  • both major sides of the functional layer are embossed by an embossing roll to form a microstructure.
  • the transparent layer and the milky layer are single or double layers
  • the combination of the transparent layer and the milky layer includes a single-layer milky layer and a single-layer transparent layer, a double-layer milky layer and a single-layer transparent layer, a single-layer milky layer and a double-layer transparent layer, and a double-layer milky layer and a double-layer transparent layer.
  • FIG. 1 is a schematic structural diagram according to the present disclosure.
  • FIG. 2 is a schematic diagram of a first embodiment according to the present disclosure.
  • FIG. 3 is a schematic diagram of a second embodiment according to the present disclosure.
  • FIG. 4 is a schematic diagram of a third embodiment according to the present disclosure.
  • FIG. 5 is a schematic diagram of a fourth embodiment according to the present disclosure.
  • a solar cell backsheet disclosed by the present disclosure, the photovoltaic backsheet from outside to inside includes a weathering layer, an adhesive layer, a polyethylene terephthalate (PET) layer, an adhesive layer, and a functional layer, wherein:
  • a thickness of the weathering layer is 5-200 ⁇ m, which is a fluorine-containing or non-fluorine-containing layer;
  • the adhesive layer is an acrylic adhesive, a polyurethane adhesive, an epoxy resin adhesive, or a resin adhesive, and the thickness is 5 ⁇ 30 ⁇ m;
  • a thickness of the PET layer is 80-400 ⁇ m.
  • the functional layer includes an integrally formed milky layer and a transparent layer, wherein:
  • the milky layer can include one layer or a plurality of layers (not more than three layers, preferably two layers), with a total thickness of 20-200 composed of a modified inorganic filler, a modified resin, an ultraviolet absorber, and an antioxidant.
  • a composition ratio is at least 3 parts of modified inorganic filler, at least 70 parts of modified resin, at least 0.3 parts of ultraviolet absorbent, and at least 0.3 parts of antioxidant.
  • each layer can be fine-tuned based on the thickness and the composition ratio of the single-layer structure, but it is necessary to ensure that the ratio of the modified resin in the layer of the milky layer combined with the transparent layer is not higher than the ratio of the modified resin in the layer of the milky layer combined with the adhesive layer, and at the same time, the thickness of the layer of the milky layer combined with the transparent layer must not be higher than the thickness of the layer of the milky layer combined with the adhesive layer.
  • the transparent layer is bonded to the cell sheet, and may also include one layer or a plurality of layers (not more than three layers, preferably two layers), with a total thickness of 200-800 ⁇ m, and composed of a modified resin, an ultraviolet absorber, and an antioxidant.
  • the composition ratio is at least 90 parts of modified resin, at least 0.3 parts of UV absorber, and at least 0.3 parts of antioxidant.
  • each layer can be fine-tuned based on the thickness and the composition ratio of the single-layer structure, but it is necessary to insure that the ratio of the modified resin in the layer of the transparent layer combined with the cell sheet is not lower than the ratio of the modified resin in the layer of the transparent layer combined with the milky layer, and at the same time, the thickness of the layer of the transparent layer combined with the cell sheet must not be higher than the thickness of the layer of the transparent layer combined with the milky layer.
  • a solar cell backsheet disclosed by the present disclosure includes a weathering layer, an adhesive layer, a PET layer, an adhesive layer, and a functional layer in sequence from outside to inside.
  • the weathering layer is a polyvinylidene fluoride (PVDF) film with a thickness of 35 ⁇ m.
  • the adhesive layer is a polyurethane adhesive with a thickness of 10 ⁇ m.
  • a thickness of the PET layer is 200 ⁇ m.
  • the functional layer includes a single-layer milky layer and a single-layer transparent layer.
  • the milky layer is adhered to the PET layer and has a thickness of 90 ⁇ m, and consists of 25 parts of polyethylene, 45 parts of polyolefin elastomer, 19 parts of polyolefin plastomer, 10 parts of titanium dioxide, 0.4 parts of antioxidant, and 0.6 parts of UV absorber.
  • the transparent layer is bonded to the cell sheet and has a thickness of 400 ⁇ m.
  • the transparent layer is composed of 60 parts of polyolefin elastomer, 39 parts of ethylene-vinyl acetate copolymer, 0.4 parts of antioxidant, and 0.4 parts of ultraviolet absorber.
  • the backsheet of this embodiment is laminated with the cell sheet, an EVA film, and glass, and then tested.
  • a peel strength between the milky layer and the transparent layer is greater than 40 N/cm
  • a peel strength between the functional layer and the PET layer is greater than 7 N/cm
  • adhesion to the cell sheet is greater than 30 N/cm
  • adhesion to the EVA of the upper layer of the cell sheet is greater than 100 N/cm.
  • the effective insulation thickness of the DTI test backsheet is greater than 340 ⁇ m, and the module is subjected to EL testing.
  • the cell sheet before and after lamination does not show cracking or fragmentation.
  • a solar cell backsheet disclosed by the present disclosure includes a weathering layer, an adhesive layer, a PET layer, an adhesive layer, and a functional layer in sequence from outside to inside.
  • the weathering layer is a weather-resistant PET having a thickness of 35 ⁇ m.
  • the adhesive layer is acrylic adhesive having a thickness of 10 ⁇ m.
  • a thickness of the PET layer is 200 ⁇ m.
  • the functional layer includes a double-layer milky layer and a single-layer transparent layer.
  • the bottom milky layer has a thickness of 90 ⁇ m and is composed of 25 parts of polyethylene, 45 parts of polyolefin elastomer, 19 parts of polyolefin plastomer, 10 parts of titanium dioxide, 0.4 parts of antioxidant, and 0.6 parts of ultraviolet absorber.
  • a thickness of the upper milky layer is 20 ⁇ m and is composed of 29 parts of polyethylene, 55 parts of polyolefin elastomer, 5 parts of polyolefin plastomer, 10 parts of titanium dioxide, 0.4 parts of antioxidant, and 0.6 parts of ultraviolet absorber.
  • the transparent layer is bonded to the cell sheet and has a thickness of 400 ⁇ m and is composed of 60 parts of olefin elastomer, 39 parts of ethylene-vinyl acetate copolymer, 0.4 parts of antioxidant, and 0.6 parts of ultraviolet absorber.
  • the backsheet of this embodiment is laminated with the cell sheet, the EVA film, and the glass and then tested.
  • the peel strength between the milky layer and the transparent layer is greater than 45 N/cm.
  • the peel strength between the functional layer and the PET layer is greater than 7 N/cm, adhesion to the cell sheet is greater than 30 N/cm, and adhesion to the EVA of the upper layer of the cell sheet is greater than 100 N/cm.
  • the effective insulation thickness of the DTI test backsheet is greater than 340 ⁇ m, and the module is subjected to EL testing.
  • the cell sheet before and after lamination does not show cracking or fragmentation.
  • a solar cell backsheet disclosed by the present disclosure includes a weathering layer, an adhesive layer, a PET layer, an adhesive layer, and a functional layer in sequence from outside to inside.
  • the weathering layer is a PVDF film with a thickness of 35
  • the adhesive layer is a polyurethane adhesive with a thickness of 10 ⁇ m.
  • a thickness of the PET layer is 200
  • the functional layer includes a single-layer milky layer and a double-layer transparent layer.
  • the milky layer has a thickness of 100 ⁇ m and is composed of 25 parts of polyethylene, 45 parts of polyolefin elastomer, 19 parts of polyolefin plastomer, 10 parts of titanium dioxide, 0.4 parts of antioxidant, and 0.6 parts of ultraviolet absorber.
  • the lower transparent layer has a thickness of 400 ⁇ m and is composed of 60 parts of polyolefin elastomer, 39 parts of ethylene-vinyl acetate copolymer, 0.4 parts of antioxidant, and 0.6 parts of ultraviolet absorber.
  • the upper transparent layer has a thickness of 20 ⁇ m and is composed of 40 parts of polyolefin elastomer, 59 parts of ethylene-vinyl acetate copolymer, 0.4 parts of antioxidant, and 0.6 parts of UV absorber.
  • the backsheet of this embodiment is laminated with the cell sheet, EVA film, and glass, and then tested.
  • the peel strength between the milky layer and the transparent layer is greater than 45 N/cm.
  • the peel strength between the functional layer and the PET layer is greater than 7 N/cm.
  • Adhesion to the cell sheet is greater than 50 N/cm.
  • Adhesion to the EVA of the upper layer of the cell sheet is greater than 120 N/cm.
  • the effective insulation thickness of the DTI test backsheet is greater than 340 ⁇ m, and the module is subjected to EL testing.
  • the cell sheet before and after lamination does not show cracking or fragmentation.
  • a solar cell backsheet disclosed by the present disclosure includes a weathering layer, an adhesive layer, a PET layer, an adhesive layer, and a functional layer in sequence from outside to inside.
  • the weathering layer is a fluorine-containing film with a thickness of 35 ⁇ m.
  • the adhesive layer is a polyurethane adhesive with a thickness of 10 ⁇ m.
  • the PET layer has a thickness of 200 ⁇ m.
  • the functional layer includes a double-layer milky layer and a double-layer transparent layer.
  • the lower milky layer has a thickness of 90 ⁇ m and is composed of 25 parts of polyethylene, 45 parts of polyolefin elastomer, 19 parts of polyolefin plastomer, 10 parts of titanium dioxide, 0.4 parts of antioxidant, and 0.6 parts of ultraviolet absorber.
  • the upper milky layer has a thickness of 30 ⁇ m and is composed of 29 parts of polyethylene, 55 parts of polyolefin elastomer, 5 parts of polyolefin plastomer, 10 parts of titanium dioxide, 0.4 parts of antioxidant, and 0.6 parts of UV absorber.
  • the lower transparent layer has a thickness of 400 ⁇ m and is composed of 60 parts of polyolefin elastomer, 39 parts of ethylene-vinyl acetate copolymer, 0.4 parts of antioxidant, and 0.6 parts of ultraviolet absorber.
  • the upper transparent layer has a thickness of 50 ⁇ m and is composed of 40 parts of polyolefin elastomer, 59 parts of ethylene-vinyl acetate copolymer, 0.4 parts of antioxidant, and 0.6 parts of ultraviolet absorber.
  • the backsheet of this embodiment is laminated with the cell sheet, EVA film, and glass, and then tested.
  • the peel strength between the milky layer and the transparent layer is greater than 50 N/cm.
  • the peel strength between the functional layer and the PET layer is greater than 7 N/cm.
  • Adhesion to the cell sheet is greater than 50 N/cm.
  • Adhesion to the EVA of the upper layer of the cell sheet is greater than 120 N/cm.
  • the effective insulation thickness of the DTI test backsheet is greater than 340 ⁇ m, and the module is subjected to EL testing.
  • the cell sheet before and after lamination does not show cracking or fragmentation.
  • the present disclosure provides a solar cell backsheet.
  • the integrated functional layer can replace the adhesive film between the cell sheet and the backsheet in the traditional module, and still provide high weatherability, high reflection, high insulation, and low water permeability to protect the module for 25-year of service life and increase the module power.
  • the disclosure discloses a solar cell backsheet, which has a functional layer that can replace the existing adhesive film layer that is in contact with the cell sheet, is integrated with the backsheet, and the functional layer adopts the transparent layer and the milky layer structure, of which the milky layer is a functional enhancement layer.
  • the peel strength of the backsheet itself can be enhanced.
  • the use of its internal formula and composition ratio causes the backsheet to have good temperature resistance, meets the requirements of high system voltage, and has high reflection and low water permeability.
  • the transparent layer is bonded to the cell, and the microporous structure on the surface can strengthen the bonding strength with the cell to greater than 40 N/cm.
  • the phase interface between the transparent layer and the milky layer is diluted, and the compatibility between the two is improved.
  • the transparent layer and the milky layer in the functional layer can be a multi-layer structure integrally extruded and obtained. It can effectively protect the cell sheet from cracking and fragmenting during the lamination process, making it reliable while improving a series of functionalities such as insulation, blocking, temperature resistance, and high reflection.
  • the solar cell backsheet disclosed by the present disclosure has the following features:
  • the integrated functional layer has a multi-layer structure.
  • the transparent layer can effectively ensure the adhesion to the cell sheet and the underlying film.
  • the transparent layer is made of polyolefin elastomer and plastomer, which can effectively protect the cell sheet from cracking and fragmenting;
  • the white structure in the integrated functional layer uses modified resin, which has good temperature resistance.
  • the conductor will not completely penetrate the substitute layer and cause it to lose its insulation effect. It is qualified for working environments with higher system voltage, greatly reducing the construction cost of the power station;

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  • Engineering & Computer Science (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Photovoltaic Devices (AREA)
US16/832,053 2017-09-27 2020-03-27 Solar cell backsheet Abandoned US20200227577A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
CN201710887257.7A CN107749428B (zh) 2017-09-27 2017-09-27 一种复合封装一体化功能性太阳能电池背板
CN201710887257.7 2017-09-27
PCT/CN2017/104026 WO2019061164A1 (zh) 2017-09-27 2017-09-28 一种复合封装一体化功能性太阳能电池背板

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PCT/CN2017/104026 Continuation-In-Part WO2019061164A1 (zh) 2017-09-27 2017-09-28 一种复合封装一体化功能性太阳能电池背板

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CN116082777A (zh) * 2022-02-10 2023-05-09 隆基乐叶光伏科技有限公司 一种黑色耐候层、光伏组件以及彩色光伏组件

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CN113327996A (zh) * 2021-05-27 2021-08-31 福斯特(嘉兴)新材料有限公司 一种透明背板
CN116082777A (zh) * 2022-02-10 2023-05-09 隆基乐叶光伏科技有限公司 一种黑色耐候层、光伏组件以及彩色光伏组件
WO2023151634A1 (zh) * 2022-02-10 2023-08-17 隆基乐叶光伏科技有限公司 一种黑色耐候层、光伏组件以及彩色光伏组件

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